Single Piece Paper Container

ABSTRACT

A container for liquids or semi-solid contents is formed from one or more pieces of paper, where the paper openings are sealed and the body of the container is coated with a material that renders the body impermeable to the contents. The coating material could be biodegradable, such that the entire container biodegrades after use. The container could also be sealed using crimping or folding the ends of the paper, and the paper could be layered to improve the impermeability effects.

This application is a continuation-in-part of co-pending U.S. application Ser. No. 12/435,918, filed May 5, 2009, which claims priority to U.S. Provisional Application No. 61/193,689, filed Dec. 16, 2008, and this application further claims the benefit of priority to U.S. Provisional Application No. 61/329,197, filed Apr. 29, 2010, all of which are incorporated herein by reference in their entirety.

Field of the Invention

The field of the invention is biodegradable containers for semi-solid compositions and liquids.

BACKGROUND

Americans currently produce more waste per capita than any other nation in the world. Much of the waste comes from plastic and/or metal, both of which decompose at a very slow rate. Some of these materials are recycled, some is dumped into the oceans or waterways, and most are deposited into landfills where they will remain for centuries. Unfortunately, plastic dispensing containers are used in almost every consumer market creating a growing problem.

In order to reduce the waste in our ever-filling landfills, it is advantageous to create containers that are more readily recyclable, biodegradable and/or compostable. In an attempt to provide a more degradable container, the use of plastics such as polylactic acid polymers (PLA) have become more commonplace. However, such plastics still require specialized processes and facilities for degradation, which results in significant costs. In addition, PLA and similar plastics are visibly indistinguishable from normal plastics. This can be problematic because if the PLA is inadvertently placed within a group of traditional plastics to be recycled, the PLA can interfere with the entire recycling process.

Various disposable containers are known in the art. US2007/0131713 to Hill, for example, teaches a disposable dispensing container. Unfortunately, Hill contemplates an inner plastic protective layer for presumably rendering the container impermeable to its contents. As such, Hill's container is far from being one hundred percent biodegradable or easily recyclable. Hill and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

EP1035025 to Lowry teaches a container having a body and a cap that is made substantially out of paper, but like Hill uses some sort of polymer or foil as a liner for rendering the container impermeable to its contents. The use of foils and polymers in Lowry impart biodegradability and recyclability issues and still contribute to our landfill problems.

Instead of a plastic layer, it is also known to coat paper to render it impermeable to liquids. U.S. Pat. No. 7,344,784 to Hodson discusses fibrous sheets that can be impregnated or otherwise coated with polymers or blends to provide resistance to liquids. Hodson contemplates that the coated sheets can then be used to manufacture many articles including jugs and cups. In addition, U.S. Pat. No. 7,048,975 to Tojo teaches a pulp molded container that utilizes a synthetic resin (like an acrylic resin) coating on the inner surface of the container for rendering it impermeable to its contents. Tojo makes a significant improvement over the previous paper containers by molding pulp fibers; but like Hill and Lowry, Tojo's synthetic resin imparts recyclability and biodegradability issues.

U.S. Pat. No. 5,217,164 to Sullivan teaches a biodegradable dispenser that uses inner and outer sleeves of paper to house a product in stick form. Sullivan contemplates coating the inner surface of the concentric peel-off sections of the inner sleeve (which defines the product lumen) to render it impermeable to the product. However, Sullivan fails to contemplate coating other areas of the inner sleeve.

It is also advantageous to create containers from one piece of paper, thereby simplifying the manufacturing process and improving the structural integrity of the container. There are single piece paper containers in the prior art, including for example the containers of WO2009/006690 to Goleby. Goleby teaches a tube made out of a single piece of paper by using an adhesive. However, the adhesive is not biodegradable and the paper is not impermeable to semi-solid or liquid compositions.

Although it is known to store sugar and salt within a paper container, for example in Pixy Sticks®, such containers are unsuitable to house semi-solid or liquid compositions since they would disintegrate in a very short time.

Thus, there is still a need for a single piece biodegradable container that is substantially impermeable to a semi-solid or liquid composition.

Definitions

The words used herein are defined below for the convenience of a reader who is skilled in the art. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

As used herein, the term “paper” means a fibrous material characterized by a plurality of discrete fibers. The filaments could be plant or animal derived, synthetic, or some combination of these. In “plant-derived fibrous materials” the filaments are at least predominantly (at least 80 or at least 90%) of plant origin, examples of which include wood, papyrus, rice, ficus, mulberry, fibers, cotton, yucca, sisal, bowstring hemp and New Zealand flax.

As used herein, the term “fibrous wall” means a wall comprising a fibrous material as a significant structural constituent. The fibrous walls contemplated herein preferably have at least 2, 5, 10, 20 or even 30 dry weight percent of fibers. Preferably, the fibrous walls have at least 80 or 90 dry weight percent of fibers. Paper is generally a fibrous material that is usually made by pressing and de-watering moist fibers, typically cellulose pulp derived from wood, rags, or grasses.

As used herein the term “substantially impermeable” means a permeation barrier that has a transfer rate of less than or equal to 50 μl of water or to sunflower oil per cm2 per six-month period of time at room temperature and normal atmospheric pressure (STP).

As used herein the term “semi-solid” means any compound having a viscosity of at least 50 to 2,000,000 Centipoise. Preferred semi-solid compositions are medium viscosity compositions having a viscosity of 2,000 to 1,000,000 Centipoise, but low viscosity compositions in the range of at least 50 to less than 2000 Centipoise, as well as high viscosity compositions in the range of 5,000 to 2,000,000 Centipoise are contemplated. Contemplated semi-solid compositions include, for example, catsup, mayonnaise, mustard, relish, salad dressing, glue, honey, shampoo, conditioner, and oil. Semi-solid compositions could include a mix of liquid, semi-solid, and solid materials. For example, damp towelettes for cleaning or disinfecting a surface are also contemplated, as are pickled vegetables.

As used herein, the term “liquid” means any compound having a viscosity of less than 50 Centipoise, or a compound that does not have any measurable “hardness.” Both water-soluble liquids and oils are contemplated, for example water, juice, urea, soy sauce, olive oil, and hinge lubricant is contemplated.

As used herein, a permeation barrier that coats “substantially all regions of the lumen” means a permeation barrier that exists somewhere on the inner surfaces of the body, between the inner and outer surfaces of the body, or on the outer surfaces of the body for at least 95% of the surfaces defining the lumen. Thus, even if a non-barrier layer is buttressed by a barrier layer, this is still “substantially all regions of the lumen.”

As used herein, “lumen” means the inner space defined by the walls of the body, whether that body be cylindrical, oval, or angular.

As used herein, a “biodegradable material” means a material that will break down to at least 90% H20, C02, and biomass within a period of six months from the action of naturally occurring micro-organisms such as bacteria, fungi, algae etc. under favorable conditions. For example, milk, baking soda, meat, plants, wood, cotton, polylactic acid polymers, and paper are all deemed herein to be biodegradable materials.

As used herein the term “container” means any compressible or non-compressible container used for housing objects, such as solids, liquids, and semi-solids.

As used herein a “tube” is a substantially cylindrical container in which the length of the container is at least 3/π times the cross-sectional area of the open end of the body taken perpendicular to a long axis of the tube. The walls of the tube typically include 1 to 5 layers (e.g., wraps).

As used herein, the term “compressible” with respect to the body means that a human user could realistically use his/her fingers to compress some portion of the walls of the body sufficiently to dispense the semi-solid or liquid composition.

As used herein, the term “sealed side” means an open side of a container that has been sealed to prevent a semi-solid or liquid product within the container from leaking out of the container through that previously open side. Thus, a side formed by folding a paper is not considered “sealed” since that side was never open. Contemplated sealing techniques comprise folding the side, crimping the side, gluing the side shut with an adhesive, and gluing a cap to the open side. Generally, the sealed side is an end of the longest length of the container, such as the ends of a tube or the ends of a rectangular box.

As used herein, “transverse seals” mean any type of seal that runs perpendicular to the longitudinal (longer) axis of the container. It is also contemplated that the sealed sides of the container could be folded inwardly to form a rim surrounding a center disc, or even have cylindrical sealed ends.

As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems and methods in which a coated paper container is constructed to be substantially impermeable to semi-solid and liquid products. The container could be constructed from a single piece of non-rigid paper, wrapped at least once, twice, thrice, four times, or more around itself to form a cylinder or in another commercially suitable shape to define a cavity that holds the product. In another embodiment, the container could be constructed from multiple pieces of paper that are layered one on top of another. The layering of the papers preferably cover more than 70, 80, or 90% of the surface area of the container. If a user were to cut a cross-sectional area of the container, the perimeter of such a cross-sectional area preferably has the layering across more than 70, 80, or 90% of the surface area of the container. In an exemplary embodiment, the container comprises at least three plies of rolled paper rolled into a tube or other cylindrical object.

The paper and the coating are both preferably made from a biodegradable material, such as a plant starch polymer or a sugar cane protein. Preferably, all parts of the container are made from biodegradable materials, such that the entire container could be considered biodegradable. This includes, for example, the walls of the container, the coating for the container, a cap to seal an opening of the container, a seal between such a cap and such an opening, a seal applied to an opening of the container, and an adhesive that couples portions of the container with one another. In an exemplary embodiment, the body of the container is made from wrapped 60 lb paper stock that is 100% post consumer waste. It is also contemplated that the walls of the body could be shaped to have polygonal, ovoid or other horizontal cross-sectional shapes. In addition, the walls could even form a cone, or be frustoconical shaped. The wall of the body of the container could be any thickness, but is preferably no more than 0.5 mm thick.

Any open sides of the container are preferably sealed to prevent any of the semi-solid or liquid products from leaking out of the open side. At least two, three, four, or more sides are sealed, and preferably all of the open sides of the container are sealed to ensure that the semi-solid or liquid products are contained within the container until a user breaks the seal or breaks a portion of the container itself. Preferably, an open side of the container is sealed by folding the side of the container upon itself, and then by crimping the folded side to create transverse seals. At least 4, 8, 10, or 20 crimps in a folded side will hold a folded paper in place and will prevent the paper from unfolding without the use of an adhesive, although an adhesive could also be used to improve the seal. In exemplary embodiments, sealed ends of the container body are tapered to form transverse seals that could be pinched, crimped, or folded, although all commercially suitable seals are contemplated. Advantageously, one or more ends of the container body could be tapered allowing a user to easily compress the tapered end of the container to dispense the semi-solid or liquid composition out an opposing end of the container body.

It is contemplated that the coating could be applied to parts of the container prior to assembly, or even after assembly. In preferred embodiments, the walls of the container comprise a rolled paper material upon which the coating has been coated on the interior and, optionally, the exterior surfaces of the walls. It is also contemplated that the coating could be: (1) on an exterior surface or interior surface of the container body; (2) impregnated within the material forming the walls of the container; and/or (3) disposed between the layers of the container body. All commercially suitable adhesives are contemplated including, for example, library paste or simply glue made from water, milk powder, vinegar and baking soda (e.g. a biodegradable adhesive). It is also contemplated that the coating could comprise a sugar coulde protein or a plant starch polymer. Other suitable coating materials include those disclosed in U.S. Pat. No. 7,344,784 to Hodson or US20050130261 to Wils.

In preferred embodiments, the coating comprises an adhesive, which could be any compound in a liquid or semi-liquid state used to adhere or bond portions of the container together, such as separate layers of paper. Contemplated adhesives include pastes (very thick) or glues (relatively fluid), or could comprise semi-solid fibrous materials that harden after being exposed to air for a period of time. For example, layers of paper could be applied one layer at a time by coating a first cylinder, waiting until that layer dries, applying a second coat, and a third coat, and so on and so forth.

In preferred embodiments, portions of the container body are compressible, to allow a user to compress one side of the container body to force the semi-solid or liquid product out another portion of the container body. For example, in the way a toothpaste tube or a Hi-C® juice drink is compressible. In an exemplary embodiment, at least the thickest portions of the container body are compressible, and the container body contains a groove at least ½ or 1 centimeter thick to allow a human user to easily push and compress the body simultaneously towards a later-opened egress of the body.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a front perspective view of an exemplary container.

FIG. 2 is a side view of the container of FIG. 1.

FIG. 3 is a front plan view of an alternative container of the present invention.

FIG. 4 is a front plan view of yet another container of the present invention.

FIG. 5 is a close-up side view of the container of FIG. 4 along the line 5-5.

FIG. 6 is a cross-sectional view of a three-ply cylindrical container.

DESCRIPTION OF THE INVENTION

One should appreciate that the disclosed techniques provide many advantageous technical effects including providing a completely biodegradable container that holds a semi-solid or liquid product without leaking.

The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

In FIGS. 1 and 2, a container 100 has a body 110 made of a single piece of paper that forms a lumen 230 that holds a semi-solid or liquid product 230 within the lumen of the body. The body 110 includes a first sealed side 120 and a second sealed side 125 that were first open when the body was rolled. First side 120 is sealed by folding lower layers of paper 130 upon itself, while second side 125 is sealed using an adhesive that is substantially impermeable to the product that seals an upper and lower side of that end. Preferably, the adhesive is also applied between layers 130 to help to improve the seal of first sealed side 120. Other commercially suitable sealings are contemplated including, for example, pinching, crimping, a threaded cap, a zip-tie, and combination(s) thereof. Although the container is shown to have a tubular shape, all commercially suitable shapes are contemplated.

Optionally, the container 100 could include a void 140, which is an area of sealed side 125 that has not been sealed with the adhesive. This allows a user who cuts along scored line 150 to have a “nozzle” that facilitates pouring of the semi-solid or liquid product 232 from the body 110. The scored line 150 could have a pre-cut notch that helps a user to tear along scored line 150 before use of product 232. Once the top portion of sealed end 125 is removed, a user could squeeze body 110 to remove product 232 from the lumen 230 of container 100 through the nozzle formed by void 140. A 1 cm groove 160 has been formed in the surface of container 110 to facilitate a user in squeezing product 232 out from container 100.

Upper surface 210 and lower surface 220 of container 100 are layered with the single piece of paper to improve the impermeability of the container, and the entire interior of lumen 230 is preferably coated with a permeation barrier to prevent product 232 from leaking through the paper walls. In a preferred embodiment, each of the layers in upper surface 210 and lower surface 220 are glued together using an adhesive that contains permeation barrier material to help facilitate the impermeability of container 100.

FIG. 3 shows an alternative embodiment of a container 300 that has a body 310. Body 310 has been folded onto itself to form a lumen holding a semi-solid or a liquid product, First side 320, second side 330, and third side 340 have been folded and crimped using transverse seals. In other embodiments, one or more of the ends 320, 330, and 340 could be sealed with a biodegradable adhesive or other commercially suitable fastener(s) including, for example, those discussed above. The crimp seals could be extended to the very edge of each side, assisting a user in tearing that side when the user wishes to access the product within container 300's lumen.

FIG. 4 illustrates an alternative embodiment of a container 400 with body 410. Here, instead of folding a paper in two, two pieces of paper have been layered one on top of another, and each one of its sealed sides 420, 430, 440, and 450 to form a lumen within body 410. The top surface and bottom surface of container 400 is preferably layered with multiple pieces of paper that have been glued to one another to provide a cardboard-type layering, increasing the non-permeability of the surfaces of container 400. Container 400 also includes a perforation or score line 460 that crosses a portion of the lumen to advantageously facilitate opening of the container 400 and thereby allow access to the contents of the lumen. In an alternative embodiment, container 400 could be composed of a single piece of paper that has been rolled and then flattened such that sides 430 and 450 are folded and have never been sealed, while sides 420 and 240 have been sealed using crimping and by applying an adhesive.

FIG. 5 shows a side view of container 400 along line 5-5, showing a close-up of the crimping. As shown, container 400 has upper layered surface 510, lower layered surface 520, and sealed side 530 with multiple transverse crimps 532 that help to seal the layers of paper against one another. Adhesive 534 also holds the sealed side closed.

FIG. 6 shows a cross-sectional view of an exemplary cylinder body 600 before it has been flattened. As shown, cylinder body 600 has outer edge 610 that has been coated with a permeation barrier, and comprises a paper 612 that has been rolled upon itself a plurality of times. Between each layer of paper adhesive 614 has been applied that contains permeation barrier material, and the interior lumen of cylinder body 600 has also been coated with a permeation barrier.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. 

1. A container comprising: a body formed from a paper, and having a first sealed side and a second sealed side, the body defining a cavity containing a product comprising at least one of a semi-solid composition and a liquid; and a coating disposed on an interior surface of the body, and configured to render an interior surface of the body substantially impermeable to the product.
 2. The container of claim 1 wherein the semi-solid composition comprises at least one of a shampoo and a conditioner.
 3. The container of claim 1 wherein the product comprises the liquid disposed on a towelette.
 4. The container of claim 1 wherein the semi-solid composition comprises at least one of catsup, mayonnaise, mustard, and soy sauce.
 5. The container of claim 1, wherein the body has at least two layers, formed from the paper, along at least 80% of a cross-sectional perimeter of the body.
 6. The container of claim 1, wherein the body has at least three layers, formed from the paper, along at least 80% of a cross-sectional perimeter of the body.
 7. The container of claim 1, wherein the body comprises at least three plies of rolled paper.
 8. The container of claim 1, wherein each of the first and second sealed sides comprise transverse seals.
 9. The container of claim 8, wherein each of the transverse seals are formed by at least one of crimping and folding.
 10. The container of claim 1, wherein the coating comprises a plant starch polymer.
 11. The container of claim 1, wherein the coating comprises a sugar cane protein.
 12. The container of claim 1, wherein the coating comprises an adhesive that couples the paper with itself.
 13. The container of claim 1, wherein the coating is further disposed on an outside surface of the body.
 14. The container of claim 5, wherein the coating is further disposed between the at least two layers of the body.
 15. The container of claim 1, wherein the coating is impregnated within the paper.
 16. The container of claim 1, wherein the body further comprises a third sealed side.
 17. The container of claim 16, wherein the body further comprises a fourth sealed side.
 18. The container of claim 1, wherein the body comprises a second paper. 